2001 CHRYSLER VOYAGER steering

Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
MASTER CYLINDER - RHD
DESCRIPTION
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 1). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
REMOVAL
CAUTION: Vacuum in the power brake booster must
be pumped down (removed) before removing mas-
ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
sucking in any contamination as the master cylin-der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle's engine not
running, until a firm feeling brake pedal is achieved.
(1) With engine not running, pump brake pedal
until a firm pedal is achieved (4 or 5 strokes).
(2) Disconnect negative battery terminal.
(3) Disconnect positive battery terminal.
(4) Remove battery shield.
(5) Remove nut and clamp securing battery to tray,
remove battery.
(6) Thoroughly clean all surfaces of the brake fluid
reservoir and master cylinder. Use only solvent such
as MopartBrake Parts Cleaner or equivalent.
(7) Remove wiring harness connector from brake
fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 1).
(8) Disconnect primary and secondary brake tubes
from master cylinder housing (Fig. 2). Install sealing
plugs in the now open brake tube outlet ports.
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(9) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
(10) Remove two nuts attaching master cylinder to
power brake booster (Fig. 2).
(11) Slide master cylinder straight out of power
brake booster.
Fig. 1 RHD MASTER CYLINDER AND POWER
BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
Fig. 2 RHD MASTER CYLINDER MOUNTING
1 - PRIMARY BRAKE TUBE NUT
2 - SECONDARY BRAKE TUBE NUT
3 - MASTER CYLINDER MOUNTING NUTS
5a - 2 BRAKES - BASERG
FLUID (Continued)

ing cable core wire through slot in bellhousing, and
disengaging cable ªTº from clutch release lever (Fig.
11).
(6) Lower vehicle.
(7) Remove steering column lower panel.
(8) Remove knee bolster.(9) Disconnect clutch cable core from upstop spacer
as shown in (Fig. 12)
Fig. 9 Clutch Cable Retainer Clip (If Equipped)
1 - RETAINER CLIP
Fig. 10 Disengaging Clip from Case (If Equipped)
1 - CABLE RETAINER
2 - SCREWDRIVER
Fig. 11 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 12 Clutch Cable at Upstop Spacer
1 - UPSTOP SPACER
2 - RELEASE CABLE
6a - 8 CLUTCHRG
CLUTCH RELEASE CABLE - LHD (Continued)

(7) Install bellhousing cap.
(8)Diesel models:Install underbody splash
shield.(9) Lower vehicle.
(10) Verify proper clutch pedal/cable operation.
(11) Install knee bolster.
(12) Install steering column lower panel.
(13) Connect battery negative cable.
Fig. 16 Clutch Cable Routing - 2.4L Gas
1 - CLUTCH RELEASE CABLE
2 - COOLANT RECOVERY BOTTLE
Fig. 17 Clutch Cable Routing - 2.5L TD
1 - CLUTCH RELEASE CABLE
2 - CABLE GUIDE
Fig. 18 Clutch Cable Retainer
1 - RETAINER
2 - CABLE GROMMET
Fig. 19 Proper Cable Retainer Installatiion
1 - RETAINER
2 - GROMMET
6a - 10 CLUTCHRG
CLUTCH RELEASE CABLE - LHD (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS.........................7
BELT TENSIONER - 2.4L
REMOVAL...............................7
INSTALLATION............................7
BELT TENSIONER - 3.3/3.8L
REMOVAL...............................8
INSTALLATION............................8
DRIVE BELTS
DESCRIPTION............................8
OPERATION.............................8
DIAGNOSIS AND TESTING..................8ACCESSORY DRIVE BELT.................8
DRIVE BELTS - 2.4L
REMOVAL...............................9
CLEANING..............................10
INSPECTION............................10
INSTALLATION...........................10
ADJUSTMENTS..........................10
DRIVE BELTS - 3.3/3.8L
REMOVAL..............................11
CLEANING..............................11
INSPECTION............................11
INSTALLATION...........................12
ACCESSORY DRIVE
SPECIFICATIONS
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE
BELTGAUGE
2.4L ENGINE
A/C Compressor/
GeneratorDynamic Tensioner
Power SteeringNew Belt: 616 N (140
lbs.)
Used Belt: 396 N (90
lbs.)
3.3/3.8L ENGINES
A/C Compressor
Dynamic Tensioner
Generator/Water
Pump/Power Steering
BELT TENSIONER - 2.4L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.(3) Remove the generator/A/C drive belt. (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove the belt tensioner (Fig. 1).
INSTALLATION
(1) Install belt tensioner and bolt (Fig. 1). Tighten
bolt to 28 N´m (250 in. lbs.).
(2) Install generator/A/C compressor drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION)
(3) Install splash shield.
(4) Lower the vehicle.
Fig. 1 Belt Tensioner - 2.4L
1 - BELT TENSIONER
2 - BOLT
RSACCESSORY DRIVE7-7

BELT TENSIONER - 3.3/3.8L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
(4) Remove the belt tensioner (Fig. 2).
INSTALLATION
(1) Install the belt tensioner and bolt (Fig. 2).
Tighten bolt to 28 N´m (250 in. lbs.).
(2) Install the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION)
(3) Install the drive belt shield.
(4) Lower the vehicle.
DRIVE BELTS
DESCRIPTION
The drive belts are a Poly-V type belt. Belt widths
vary depending on the various engine and accessory
packages. Satisfactory performance of these belts
depends on belt condition and proper belt tension.
OPERATION
The accessory drive belts form the link between
the engine crankshaft and the engine driven accesso-
ries.
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley5. Replace pulley
Fig. 2 BELT TENSIONER - 3.3/3.8L
1 - BELT TENSIONER
2 - BOLT
7 - 8 ACCESSORY DRIVERS

CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b) Adjust power steering belt
tension (4 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
DRIVE BELTS - 2.4L
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 3).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 3).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (D)
and (F) (Fig. 4).
(2) From under the vehicle, loosen the pivot bolt
(E). Loosen adjusting bolt (G) until belt can be
removed.
Fig. 3 A/C & GENERATOR BELT TENSION RELEASE
1 - BELT TENSIONER
2 - WRENCH
Fig. 4 Power Steering Pump
1 - REAR LOCKING NUT (D)
2 - ADJUSTING BOLT (G)
3 - PIVOT BOLT (E)
4 - FRONT LOCKING NUT (F)
RSACCESSORY DRIVE7-9
DRIVE BELTS (Continued)

CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 5).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
GENERATOR AND AIR CONDITIONING BELT
(1) Install belt onto all pulleys except for the
crankshaft (Fig. 6).
(2) Rotate belt tensioner clockwise until belt can
be installed onto the crankshaft pulley (Fig. 3).
Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys (Fig. 6).
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
POWER STEERING PUMP
(1) Install belt over crankshaft and power steering
pump pulleys (Fig. 6).
(2) Apply an initial snug torque to fasteners (D),
(E), and (F) (Fig. 4).
(3) Tighten adjusting bolt (G) until the proper ten-
sion obtained (Fig. 4). Refer to Belt Tension Specifi-
cations (Refer to 7 - COOLING/ACCESSORY DRIVE
- SPECIFICATIONS).
(4) Tighten locking nuts (D) and (F) to 54 N´m (40
ft. lbs.) (Fig. 4).
(5) Tighten pivot bolt (E) to 54 N´m (40 ft. lbs.)
(Fig. 4).
ADJUSTMENTS
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
7198. Because of space limitations in the engine com-
partment, the use of this gauge may be restricted.
Raise the vehicle on a hoist and the remove the
splash shield to gain access to the drive belts, if nec-
essary. Adjust belt tension for either aNeworUsed
belt. For specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE - SPECIFICATIONS).
Fig. 5 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
Fig. 6 Accessory Drive Belts - 2.4L
1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS - 2.4L (Continued)

INSTALLATION
(1) Route and position the drive belt onto all pul-
leys, except for the crankshaft (Fig. 10).(2) Rotate belt tensioner counterclockwise until
belt can be installed onto the crankshaft pulley (Fig.
8). Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys.
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
Fig. 10 ACCESSORY DRIVE BELT
1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY
7 - 12 ACCESSORY DRIVERS
DRIVE BELTS - 3.3/3.8L (Continued)